The WIA Wirefeeder W64-1 is an essential component for Gas Metal Arc Welding (GMAW) processes, designed to feed consumable wire to a welding gun. This wirefeeder is suitable for a wide range of applications, from sheet-metal work to heavy plate welding, and can handle various metals including carbon steel, aluminum alloys, and stainless steel. It is engineered to work with both solid and flux-cored wires, offering versatility for different welding requirements.
Function Description
The W64-1 Wirefeeder's primary function is to precisely control the feeding of consumable welding wire from a spool to the welding gun. This process is critical for GMAW, where the arc is struck between the workpiece and the wire, which then melts into the weld pool. The wirefeeder ensures a consistent and smooth wire feed, which is vital for stable arc performance and quality welds. It incorporates a compact motor with an integral gearbox coupled to a 4-roll drive assembly, providing robust and reliable wire feeding. An electronic speed control regulates the motor, compensating for supply voltage variations and ensuring consistent wire speed.
The wirefeeder features several controls to fine-tune the welding process:
- Power On Indicator: Illuminates when the wirefeeder and power source are active.
- Arc Start Control: Adjusts the initial wire acceleration, with 'SOFT' for slower acceleration suitable for larger diameter and aluminum wires, and 'FAST' for quicker starts, ideal for rapid tack welding.
- Wire Speed Control: Regulates the wire drive motor speed, allowing adjustment of the wire feed rate from 0 to 20 meters per minute (0-172 RPM). This control is used in conjunction with the Wire Speed Range Select Switch.
- Wire Speed Range Indicator Light: Indicates whether the wirefeeder is operating in High Speed (8-20 meters/min) or Low Speed (0-10 meters/min) range.
- Wire Speed Range Select Switch: Toggles between Low and High wire speed ranges.
- Purge Button: Activates the gas solenoid valve without energizing the welding power source, useful for purging gas lines.
- Inch Button: Feeds wire without energizing the welding power source, allowing the operator to set the wire at the current wire speed.
- Latch Select Button and Indicator: When 'Latch' mode is selected, the gun switch momentarily starts welding and then stops, useful for long welding runs.
- Pre Gas Control (Inside Panel): Sets the duration of gas flow before welding commences (0-2 seconds).
- Post Gas Control (Inside Panel): Sets the duration of gas flow after welding ceases (0-2 seconds).
- Spot Time Control (Inside Panel): When set clockwise, the welder operates for a short, adjustable time (up to 5 seconds) after each trigger press, useful for spot welding.
- Burnback Control (Inside Panel): Adjusts the time welding voltage continues after the gun switch is released and wire feed stops, preventing the wire from freezing in the weld pool.
Important Technical Specifications
- Supply Voltage: 32 volts AC (from welding power source)
- Rated Supply Current: 5 Amps
- Pre-gas Range: 0 - 2 seconds
- Post-gas Range: 0 - 10 seconds
- Start Speed: Normal or Creep (switchable)
- Spool Sizes: 5 kg, 15 kg
- Wirespeed Range: 0 - 172 RPM; 0 - 20 Metres per minute (Low Speed Range: 0 - 10 Metres per minute; High Speed Range: 8 - 20 Metres per minute)
- Wire Size Range: 0.6mm - 1.6mm diameter
The wirefeeder is designed to accommodate various wire types, including solid wire (0.6mm to 1.6mm), aluminum wire (1.0mm to 1.2mm), and flux-cored wire (1.0mm to 1.6mm). It comes with 0.9/1.2 V Groove drive rolls fitted as standard, with other sizes available.
Usage Features
The W64-1 Wirefeeder is designed for ease of use and adaptability.
- Remote Wirefeeder: It connects to a Weldmatic power source via a composite cable interconnecting lead, ensuring reliable electrical contact and gas supply.
- Consumable Wire Feeding: The 4-roll drive assembly ensures smooth and consistent wire feeding. The top roller arms can be adjusted to provide sufficient clamping pressure without deforming the wire.
- Spool Holder: The wire spool is placed on a holder with an adjustable brake to prevent overrun when the motor stops.
- Gun and Cable Assembly: The wirefeeder is compatible with 350 Amp and 400 Amp torches, featuring Euro connector points for easy attachment.
- Drive Rolls: The wirefeeder is supplied with WF027 bottom rollers suitable for both 0.9mm and 1.2mm diameter steel wire. Other drive roll sizes are available for different wire types and diameters.
- Liner Replacement: The manual provides clear instructions for replacing the gun cable liner, a critical consumable for smooth wire feeding. This involves disconnecting the gun/cable assembly, removing the nozzle, gas diffuser, and insulator, cutting the new liner to the correct length, and reassembling.
Maintenance Features
Regular maintenance is crucial for the optimal performance and longevity of the W64-1 Wirefeeder.
- Dust and Dirt Removal: It is recommended to regularly remove accumulated dust and dirt from within the wirefeeder using dry, low-pressure compressed air or a vacuum cleaner. This should be done at least every 12 months, or more frequently in dusty environments, to prevent PCB component failure.
- Wirefeed System Checks:
- Feed Rolls: Ensure the correct size and type of feed rolls are used for the wire, that the drive groove aligns with the wire, and that the groove is not worn.
- Gun Cable Liner: Keep the liner clear of dust and swarf. Regular purging with dry compressed air is recommended, especially when replacing the wire spool. Replace the liner when necessary.
- Welding Tip: Ensure the tip is free of obstructions like spatter. Ream out the tip bore with a suitable cleaner and replace when worn.
- Feed Roll Pressure: Adjust pressure to be just sufficient for even wire feeding, avoiding excessive pressure that can deform the electrode wire.
- Spool Holder: Verify that the spool holder rotates smoothly and that the braking action prevents overrun without being excessive.
- Welding Wire Quality: Check that the welding wire is straight, free of buckles or waviness, and free of surface rust. Replace buckled or rusty wire.
- Safety Precautions: Always disconnect the equipment from the mains power supply before removing covers or performing maintenance, as lethal voltages are present when energized.
The WIA Wirefeeder W64-1 is a robust and versatile tool designed to deliver consistent and high-quality welding performance, supported by comprehensive controls and straightforward maintenance procedures.
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